EP3024639B1 - Method for injection molding a part made of a composite material having advance pre-consolidation of the fibrous preform - Google Patents

Method for injection molding a part made of a composite material having advance pre-consolidation of the fibrous preform Download PDF

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Publication number
EP3024639B1
EP3024639B1 EP14755864.7A EP14755864A EP3024639B1 EP 3024639 B1 EP3024639 B1 EP 3024639B1 EP 14755864 A EP14755864 A EP 14755864A EP 3024639 B1 EP3024639 B1 EP 3024639B1
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EP
European Patent Office
Prior art keywords
resin
consolidation
fiber preform
preform
injection mold
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EP14755864.7A
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German (de)
French (fr)
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EP3024639A1 (en
Inventor
Bastien TRANQUART
Sébastien PAUTARD
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Safran SA
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Safran SA
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Publication of EP3024639A1 publication Critical patent/EP3024639A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/071—Preforms or parisons characterised by their configuration, e.g. geometry, dimensions or physical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/07—Preforms or parisons characterised by their configuration
    • B29C2949/0715—Preforms or parisons characterised by their configuration the preform having one end closed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12—Thermoplastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/20—Inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2713/00—Use of textile products or fabrics for preformed parts, e.g. for inserts

Definitions

  • the present invention relates to the general field of manufacture of composite material parts comprising a fiber reinforcement densified by a matrix.
  • It relates more specifically to a process for injection molding a composite material part, for example in the aeronautical field.
  • an injection molding process consists of placing a fiber preform in an injection mold, injecting a liquid resin under pressure into the injection mold so as to impregnate the preform, polymerize the resin, then unmould the piece.
  • the resins used are generally thermosetting or thermoplastic resins.
  • the appearance of defects on the fibrous preform during the resin injection phase generates changes in the local mechanical properties in the final part, in particular module abutments and changes in the axes of the warp and weft threads. as well as post-injection deformities.
  • thermoplastic resins when using thermoplastic resins, these defects are amplified by the high injection pressures that are necessary to take account of the high viscosity of these resins.
  • additives to limit the viscosity of these resins is also not sufficient to overcome such drawbacks.
  • the present invention therefore has the main purpose of providing an injection molding process which does not have the aforementioned drawbacks.
  • an injection molding process of a composite material part comprising a fiber reinforcement densified by a matrix comprising successively the placement of a fibrous preform in an injection mold, the injection under pressure in the mold of a thermoplastic resin so as to impregnate the preform and the polymerization of the resin, and wherein, in accordance with the invention, the fibrous preform is consolidated in the injection mold prior to the injection of the resin.
  • the invention provides a step of consolidating the fiber preform prior to injection of the resin. This pre-consolidation of the fiber preform thus makes it possible to limit the effects of decadration on the preform during the injection of the polymerization resin. The homogeneity of the mechanical properties of the part obtained is thus greatly improved.
  • the method comprises a step of consolidating the fibrous preform prior to the injection of the resin into the injection mold comprising the production of a fibrous preform inside which a consolidation resin is present, the placing the fibrous preform in a consolidation tool, heating the consolidation tool to the melting temperature of the consolidation resin present inside the fibrous preform, and solidifying the consolidation resin.
  • the production of a fibrous preform within which a consolidation resin is present may include the insertion of consolidation resin threads during weaving of the fibrous preform.
  • the production of a fiber preform within which a consolidation resin is present may comprise the powdering of the fibrous preform by a consolidation resin in powder form.
  • the consolidation step of the fiber preform may further comprise the application of a compacting pressure of the fiber preform in the consolidation tool.
  • a compaction pressure makes it possible to limit the porosity in the preform and to optimize its positioning in the consolidation tooling and its final shaping to obtain left-handed shapes.
  • the consolidation resin is identical to that injected into the injection mold so as to optimize the cohesive and adhesive aspects.
  • the consolidation step of the fibrous preform is carried out using a consolidation tool that corresponds to the injection mold. In this case, the manufacturing time of the composite material part is shortened because there is no transfer of the consolidated preform to be performed.
  • the invention applies to the production of composite material parts comprising a fiber reinforcement densified by a matrix. It applies more particularly to the production of parts used in the aeronautical field (for example fan blades or stator vanes) by a liquid resin injection molding process in which the resin is a thermoplastic resin.
  • the liquid resin injection molding process consists in injecting under pressure a liquid resin into an injection mold in which a fiber preform of the part to be manufactured has been placed beforehand.
  • the polymerization of the thermoplastic resin takes place during a cooling cycle of the preform with a regulation of the tooling temperature. Once the resin has polymerized, the part is demolded.
  • the injection pressure of the liquid resin in the injection mold varies in particular according to the nature of the resin.
  • the pressure is between 500 and 2400 bar for a thermoplastic resin (as an indication, it is generally between 10 and 30 bar for a thermosetting resin).
  • the fibrous preform can be obtained in various ways known to those skilled in the art. It may in particular be a preform obtained directly by three-dimensional weaving (3D), two-dimensional (2D) or 2.5D yarn (formed for example of carbon fibers) or by draping or stacking two-dimensional fiber tissue sequences.
  • 3D three-dimensional weaving
  • 2D two-dimensional
  • 2.5D yarn formed for example of carbon fibers
  • the nature of the resin depends in particular on the nature of the threads used to form the fiber preform.
  • a preform made from carbon or glass son it is possible to use a thermoplastic resin, for example a resin made from phenylene polysulfide and / or polyetherimide and / or polyetherketone or a mixture of these components.
  • this resin may optionally be loaded, for example by short or long fibers, flakes ("flakes" in English), beads, mineral fillers, nano-fillers, etc.
  • the injection molding process according to the invention comprises, prior to the actual molding process (E10), consolidation of the fibrous preform (E20).
  • the consolidation of the fibrous preform prior to its placement in the injection mold consists first of all in producing a fibrous preform inside which a consolidation resin is present (step E20 -1).
  • the consolidation resin is a thermoplastic resin which is preferably identical to the resin injected into the injection mold during the actual molding process. This consolidation resin is used directly for producing the fiber preform according to different techniques.
  • the consolidation resin may be different from that which is injected into the injection mold. Indeed, some polymers have sufficient chemical compatibility for the cohesive / adhesive aspect.
  • consolidation resin threads are inserted directly into the fibrous preform during weaving thereof.
  • consolidation resin threads are used during weaving to replace some of the fibers of the fiber preform.
  • son of the same nature as those of the injected resin will be used.
  • consolidation resin packaged in powder form is sprinkled directly onto the fiber preform once it has been made.
  • the fiber preform is made using son coated with consolidation resin (that is to say son treated by sizing).
  • This consolidation tool may be a compression tool, a stamping tool, an injection-compression mold, according to embodiments that are not part of the present invention, or even, according to the present invention, the same injection mold that used during the molding process itself.
  • the consolidation tooling is carried out in the same injection mold as used during the molding process with a movable core (heated) or in a rotary mold with several stages (1 st phase of consolidation with core / dedicated fingerprint, 2 nd phase of opening and rotation / translation of the mold, and 3 rd phase of closing the mold with a new cavity that will allow the injection of the resin on the preform and pre-consolidated).
  • the consolidation tool is then heated (step E20-3) until a temperature higher than the glass transition temperature of the consolidation resin.
  • a compacting pressure can be added during the heating of the consolidation tool (step E20-4), in particular to limit the porosity in the consolidated fiber preform and to optimize positioning and forming thereof in the consolidation tool.
  • Solidification of the consolidation resin can then be initiated (step E20-5). This solidification is obtained during the cooling cycle at a given and optimum temperature of the consolidation tool.
  • the fibrous preform is ejected from the consolidation tool (step E20-6).
  • the preform obtained is consolidated thanks to the consolidation resin which was present inside the preform and which polymerized within it.
  • the consolidated fiber preform is rigid and can be easily handled.
  • the fiber preform is rigid enough that the injection of resin under pressure during the actual molding does not generate deformation of the preform.
  • step E10 The molding process itself can then start (step E10).
  • the consolidated fiber preform is placed in the injection mold (step E10-1), according to an embodiment which does not form part of the present invention.
  • this step, as well as the step E20-6 ejection of the preform of the consolidation tool, are not necessary if the consolidation tool used is the injection mold, as it is the case in the present invention.
  • the liquid resin is injected under pressure into it (step E10-2) so as to be polymerized therein (by cooling - step E10-3).
  • step E10-4) is then demolded (step E10-4) and optionally machined to the desired final shapes.
  • the pre-consolidation of the fibrous preform can itself be a finished part and the actual injection process will make it possible to add specific functionalities to these (by injection and overmolding of elements in the part such as fastening clips, drums for screwing, metal heels, positioning ribs, etc.).

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Reinforced Plastic Materials (AREA)

Description

Arrière-plan de l'inventionBackground of the invention

La présente invention se rapporte au domaine général de la fabrication de pièces en matériau composite comprenant un renfort fibreux densifié par une matrice.The present invention relates to the general field of manufacture of composite material parts comprising a fiber reinforcement densified by a matrix.

Elle concerne plus précisément un procédé de moulage par injection d'une pièce en matériau composite, par exemple dans le domaine aéronautique.It relates more specifically to a process for injection molding a composite material part, for example in the aeronautical field.

De façon connue, un procédé de moulage par injection consiste à placer une préforme fibreuse dans un moule d'injection, à injecter une résine liquide sous pression dans le moule d'injection de manière à imprégner la préforme, à polymériser la résine, puis à démouler la pièce. Dans le cas d'un matériau composite à matrice organique, les résines utilisées sont généralement des résines thermodurcissables ou thermoplastiques.In known manner, an injection molding process consists of placing a fiber preform in an injection mold, injecting a liquid resin under pressure into the injection mold so as to impregnate the preform, polymerize the resin, then unmould the piece. In the case of an organic matrix composite material, the resins used are generally thermosetting or thermoplastic resins.

Le document WO 98 50 211 A1 divulgue à cet égard un procédé de moulage par injection selon le préambule de la revendication 1. Avec ce type de procédé, il est fréquent que l'injection de résine sous pression dans le moule d'injection crée des défauts sur la préforme, notamment des problèmes de positionnement des fils de la préforme (certains fils de la préforme ont tendance à bouger) et des problèmes de décadrage inter laminaire (c'est-à-dire de déformation entre deux plies différentes).The document WO 98501111 A1 discloses in this regard an injection molding method according to the preamble of claim 1. With this type of process, it is common for the injection of resin under pressure in the injection mold creates defects on the preform, including problems of positioning the son of the preform (some son of the preform tend to move) and problems of inter-laminar decadration (that is to say deformation between two different plaice).

Or, l'apparition de défauts sur la préforme fibreuse lors de la phase d'injection de résine génère des modifications des propriétés mécaniques locales dans la pièce finale, en particulier des abattements des modules et des modifications des axes des fils de chaîne et de trame, ainsi que des déformées post-injection.However, the appearance of defects on the fibrous preform during the resin injection phase generates changes in the local mechanical properties in the final part, in particular module abutments and changes in the axes of the warp and weft threads. as well as post-injection deformities.

De plus, en cas d'utilisation de résines thermoplastiques, ces défauts sont amplifiés par les fortes pressions d'injection qui sont nécessaires pour tenir compte de la viscosité élevée de ces résines. L'ajout d'additifs permettant de limiter la viscosité de ces résines n'est par ailleurs pas suffisant pour pallier de tels inconvénients.In addition, when using thermoplastic resins, these defects are amplified by the high injection pressures that are necessary to take account of the high viscosity of these resins. The addition of additives to limit the viscosity of these resins is also not sufficient to overcome such drawbacks.

Objet et résumé de l'inventionObject and summary of the invention

La présente invention a donc pour but principal de proposer un procédé de moulage par injection qui ne présente pas les inconvénients précités.The present invention therefore has the main purpose of providing an injection molding process which does not have the aforementioned drawbacks.

Ce but est atteint grâce à un procédé de moulage par injection d'une pièce en matériau composite comprenant un renfort fibreux densifié par une matrice, le procédé comprenant successivement le placement d'une préforme fibreuse dans un moule d'injection, l'injection sous pression dans le moule d'une résine thermoplastique de manière à imprégner la préforme et la polymérisation de la résine, et dans lequel, conformément à l'invention, la préforme fibreuse est consolidée dans le moule d'injection préalablement à l'injection de la résine.This object is achieved by an injection molding process of a composite material part comprising a fiber reinforcement densified by a matrix, the method comprising successively the placement of a fibrous preform in an injection mold, the injection under pressure in the mold of a thermoplastic resin so as to impregnate the preform and the polymerization of the resin, and wherein, in accordance with the invention, the fibrous preform is consolidated in the injection mold prior to the injection of the resin.

Par rapport aux procédés de moulage par injection connus, l'invention prévoit une étape consistant à consolider la préforme fibreuse préalablement à l'injection de la résine. Cette pré-consolidation de la préforme fibreuse permet ainsi de limiter les effets de décadrage sur la préforme lors de l'injection de la résine de polymérisation. L'homogénéité des propriétés mécaniques de la pièce obtenue s'en trouve ainsi grandement améliorée.Compared to known injection molding processes, the invention provides a step of consolidating the fiber preform prior to injection of the resin. This pre-consolidation of the fiber preform thus makes it possible to limit the effects of decadration on the preform during the injection of the polymerization resin. The homogeneity of the mechanical properties of the part obtained is thus greatly improved.

De préférence, le procédé comprend une étape de consolidation de la préforme fibreuse préalablement à l'injection de la résine dans le moule d'injection comprenant la réalisation d'une préforme fibreuse à l'intérieur de laquelle une résine de consolidation est présente, la mise en place de la préforme fibreuse dans un outillage de consolidation, le chauffage de l'outillage de consolidation à la température de fusion de la résine de consolidation présente à l'intérieur de la préforme fibreuse, et la solidification de la résine de consolidation.Preferably, the method comprises a step of consolidating the fibrous preform prior to the injection of the resin into the injection mold comprising the production of a fibrous preform inside which a consolidation resin is present, the placing the fibrous preform in a consolidation tool, heating the consolidation tool to the melting temperature of the consolidation resin present inside the fibrous preform, and solidifying the consolidation resin.

La réalisation d'une préforme fibreuse à l'intérieur de laquelle une résine de consolidation est présente peut comprendre l'insertion de fils de résine de consolidation au cours du tissage de la préforme fibreuse.The production of a fibrous preform within which a consolidation resin is present may include the insertion of consolidation resin threads during weaving of the fibrous preform.

Alternativement, la réalisation d'une préforme fibreuse à l'intérieur de laquelle une résine de consolidation est présente peut comprendre le poudrage de la préforme fibreuse par une résine de consolidation sous forme de poudre.Alternatively, the production of a fiber preform within which a consolidation resin is present may comprise the powdering of the fibrous preform by a consolidation resin in powder form.

Encore alternativement, la réalisation d'une préforme fibreuse à l'intérieur de laquelle une résine de consolidation est présente peut comprendre la réalisation d'une préforme fibreuse à l'aide de fils enduits de résine de consolidation.Still alternatively, the production of a fibrous preform within which a consolidation resin is present can understanding the production of a fibrous preform using son coated with consolidation resin.

Par ailleurs, l'étape de consolidation de la préforme fibreuse peut comprendre en outre l'application d'une pression de compactage de la préforme fibreuse dans l'outillage de consolidation. L'application d'une telle pression de compactage permet de limiter la porosité dans la préforme et d'optimiser son positionnement dans l'outillage de consolidation et sa mise en forme finale pour l'obtention de formes gauches.Furthermore, the consolidation step of the fiber preform may further comprise the application of a compacting pressure of the fiber preform in the consolidation tool. The application of such a compaction pressure makes it possible to limit the porosity in the preform and to optimize its positioning in the consolidation tooling and its final shaping to obtain left-handed shapes.

De préférence également, la résine de consolidation est identique à celle injectée dans le moule d'injection de façon à optimiser les aspects cohésifs et adhésifs.Also preferably, the consolidation resin is identical to that injected into the injection mold so as to optimize the cohesive and adhesive aspects.

L'étape de consolidation de la préforme fibreuse est réalisée à l'aide d'un outillage de consolidation qui correspond au moule d'injection. Dans ce cas, le temps de fabrication de la pièce en matériau composite est raccourci car il n'y a pas de transfert de la préforme consolidée à effectuer.The consolidation step of the fibrous preform is carried out using a consolidation tool that corresponds to the injection mold. In this case, the manufacturing time of the composite material part is shortened because there is no transfer of the consolidated preform to be performed.

Brève description du dessinBrief description of the drawing

D'autres caractéristiques et avantages de la présente invention ressortiront de la description faite ci-dessous, en référence à la figure unique annexée qui en illustre un exemple de réalisation dépourvu de tout caractère limitatif.Other features and advantages of the present invention will emerge from the description given below, with reference to the single appended figure which illustrates an embodiment having no limiting character.

Description détaillée de l'inventionDetailed description of the invention

L'invention s'applique à la réalisation de pièces en matériau composite comprenant un renfort fibreux densifié par une matrice. Elle s'applique plus particulièrement à la réalisation de pièces utilisées dans le domaine aéronautique (par exemple des aubes de soufflante ou des aubes de redresseur) par un procédé de moulage par injection de résine liquide dans lequel la résine est une résine thermoplastique.The invention applies to the production of composite material parts comprising a fiber reinforcement densified by a matrix. It applies more particularly to the production of parts used in the aeronautical field (for example fan blades or stator vanes) by a liquid resin injection molding process in which the resin is a thermoplastic resin.

De façon bien connue en soi, le procédé de moulage par injection de résine liquide consiste à injecter sous pression une résine liquide dans un moule d'injection dans lequel une préforme fibreuse de la pièce à fabriquer a été préalablement placée. La polymérisation de la résine thermoplastique s'effectue pendant un cycle de refroidissement de la préforme avec une régulation de la température de l'outillage. Une fois la résine polymérisée, la pièce est démoulée.In a manner well known per se, the liquid resin injection molding process consists in injecting under pressure a liquid resin into an injection mold in which a fiber preform of the part to be manufactured has been placed beforehand. The polymerization of the thermoplastic resin takes place during a cooling cycle of the preform with a regulation of the tooling temperature. Once the resin has polymerized, the part is demolded.

La pression d'injection de la résine liquide dans le moule d'injection varie notamment en fonction de la nature de la résine. Typiquement, pour une pièce aéronautique, la pression est comprise entre 500 et 2400 bars pour une résine thermoplastique (à titre indicatif, elle est généralement comprise entre 10 et 30 bars pour une résine thermodurcissable).The injection pressure of the liquid resin in the injection mold varies in particular according to the nature of the resin. Typically, for an aeronautical part, the pressure is between 500 and 2400 bar for a thermoplastic resin (as an indication, it is generally between 10 and 30 bar for a thermosetting resin).

La préforme fibreuse peut être obtenue de différentes façons connues de l'homme du métier. Il peut notamment s'agir d'une préforme obtenue directement par tissage tridimensionnel (3D), bidimensionnel (2D) ou 2,5D de fils (formés par exemple de fibres de carbone) ou par drapage ou empilement de séquences de tissus fibreux bidimensionnels.The fibrous preform can be obtained in various ways known to those skilled in the art. It may in particular be a preform obtained directly by three-dimensional weaving (3D), two-dimensional (2D) or 2.5D yarn (formed for example of carbon fibers) or by draping or stacking two-dimensional fiber tissue sequences.

La nature de la résine dépend notamment de la nature des fils utilisés pour former la préforme fibreuse. Pour une préforme réalisée à partir de fils de carbone ou de verre, on pourra utiliser une résine thermoplastique, par exemple une résine réalisée à partir de polysulfure de phénylène et/ou de polyétherimide et/ou de polyéthercétone ou un mélange de ces composants. De plus, cette résine peut éventuellement être chargée, par exemple par des fibres courtes ou longues, des écailles (« flakes » en anglais), billes, charges minérales, des nano-charges, etc.The nature of the resin depends in particular on the nature of the threads used to form the fiber preform. For a preform made from carbon or glass son, it is possible to use a thermoplastic resin, for example a resin made from phenylene polysulfide and / or polyetherimide and / or polyetherketone or a mixture of these components. In addition, this resin may optionally be loaded, for example by short or long fibers, flakes ("flakes" in English), beads, mineral fillers, nano-fillers, etc.

Conformément à l'invention, le procédé de moulage par injection selon l'invention comprend, préalablement au processus de moulage proprement dit (E10), une consolidation de la préforme fibreuse (E20).According to the invention, the injection molding process according to the invention comprises, prior to the actual molding process (E10), consolidation of the fibrous preform (E20).

Plus précisément, comme représenté sur la figure, la consolidation de la préforme fibreuse préalablement à son placement dans le moule d'injection, consiste en premier lieu à réaliser une préforme fibreuse à l'intérieur de laquelle une résine de consolidation est présente (étape E20-1).More specifically, as shown in the figure, the consolidation of the fibrous preform prior to its placement in the injection mold, consists first of all in producing a fibrous preform inside which a consolidation resin is present (step E20 -1).

La résine de consolidation est une résine thermoplastique qui est de préférence identique à la résine injectée dans le moule d'injection lors du processus de moulage proprement dit. Cette résine de consolidation est utilisée directement pour la réalisation de la préforme fibreuse selon différentes techniques.The consolidation resin is a thermoplastic resin which is preferably identical to the resin injected into the injection mold during the actual molding process. This consolidation resin is used directly for producing the fiber preform according to different techniques.

Lorsqu'elle est de nature thermoplastique, la résine de consolidation peut être différente de celle qui est injectée dans le moule d'injection. En effet, certains polymères ont une compatibilité chimique suffisante pour l'aspect cohésif/adhésif.When it is of a thermoplastic nature, the consolidation resin may be different from that which is injected into the injection mold. Indeed, some polymers have sufficient chemical compatibility for the cohesive / adhesive aspect.

Selon l'une de ces techniques, des fils de résine de consolidation sont insérés directement dans la préforme fibreuse au cours du tissage de celle-ci. A cet effet, des fils de résine de consolidation sont utilisés au cours du tissage en remplacement de certains des fils de la préforme fibreuse. De préférence, on utilisera des fils de même nature que ceux de la résine injectée.According to one of these techniques, consolidation resin threads are inserted directly into the fibrous preform during weaving thereof. For this purpose, consolidation resin threads are used during weaving to replace some of the fibers of the fiber preform. Preferably, son of the same nature as those of the injected resin will be used.

Selon une autre technique, de la résine de consolidation conditionnée sous forme de poudre est saupoudrée directement sur la préforme fibreuse une fois celle-ci réalisée.According to another technique, consolidation resin packaged in powder form is sprinkled directly onto the fiber preform once it has been made.

Selon encore une autre technique, la préforme fibreuse est réalisée à l'aide de fils enduits de résine de consolidation (c'est-à-dire des fils traités par ensimage).According to yet another technique, the fiber preform is made using son coated with consolidation resin (that is to say son treated by sizing).

Une fois obtenue la préforme fibreuse à l'intérieur de laquelle une résine de consolidation est présente, celle-ci est placée dans un outillage de consolidation (étape E20-2).Once obtained the fibrous preform inside which a consolidation resin is present, it is placed in a consolidation tool (step E20-2).

Cet outillage de consolidation peut être un outillage de compression, d'estampage, un moule d'injection-compression, selon des modes de réalisation qui ne font pas partie de la présente invention, ou bien encore, conformément à la présente invention, le même moule d'injection que celui utilisé lors du processus de moulage proprement dit. Selon l'invention, l'outillage de consolidation est réalisé dans le même moule d'injection que celui utilisé lors du processus de moulage avec un noyau mobile (chauffé) ou dans un moule rotatif avec plusieurs phases (1ère phase de consolidation avec noyau/empreinte dédié, 2ème phase d'ouverture et de rotation/translation du moule, et 3ème phase de fermeture du moule avec une nouvelle cavité qui permettra l'injection de la résine sur la préforme ainsi pré-consolidée).This consolidation tool may be a compression tool, a stamping tool, an injection-compression mold, according to embodiments that are not part of the present invention, or even, according to the present invention, the same injection mold that used during the molding process itself. According to the invention, the consolidation tooling is carried out in the same injection mold as used during the molding process with a movable core (heated) or in a rotary mold with several stages (1 st phase of consolidation with core / dedicated fingerprint, 2 nd phase of opening and rotation / translation of the mold, and 3 rd phase of closing the mold with a new cavity that will allow the injection of the resin on the preform and pre-consolidated).

L'outillage de consolidation est alors chauffé (étape E20-3) jusqu'à atteindre une température supérieure à la température de transition vitreuse de la résine de consolidation.The consolidation tool is then heated (step E20-3) until a temperature higher than the glass transition temperature of the consolidation resin.

Si nécessaire, une pression de compactage peut être ajoutée lors du chauffage de l'outillage de consolidation (étape E20-4), notamment pour limiter la porosité dans la préforme fibreuse consolidée et optimiser le positionnement et le formage de celle-ci dans l'outillage de consolidation.If necessary, a compacting pressure can be added during the heating of the consolidation tool (step E20-4), in particular to limit the porosity in the consolidated fiber preform and to optimize positioning and forming thereof in the consolidation tool.

La solidification de la résine de consolidation peut alors être déclenchée (étape E20-5). Cette solidification est obtenue pendant le cycle de refroidissement à une température donnée et optimale de l'outillage de consolidation.Solidification of the consolidation resin can then be initiated (step E20-5). This solidification is obtained during the cooling cycle at a given and optimum temperature of the consolidation tool.

Après cette étape de solidification de la résine de consolidation, la préforme fibreuse est éjectée de l'outillage de consolidation (étape E20-6). La préforme obtenue est consolidée grâce à la résine de consolidation qui était présente à l'intérieur de la préforme et qui s'est polymérisée au sein de celle-ci.After this step of solidification of the consolidation resin, the fibrous preform is ejected from the consolidation tool (step E20-6). The preform obtained is consolidated thanks to the consolidation resin which was present inside the preform and which polymerized within it.

A ce stade, la préforme fibreuse consolidée est rigide et peut être aisément manipulée. En particulier, la préforme fibreuse est suffisamment rigide pour que l'injection de résine sous pression au cours du moulage proprement dit ne génère pas de déformation de la préforme.At this stage, the consolidated fiber preform is rigid and can be easily handled. In particular, the fiber preform is rigid enough that the injection of resin under pressure during the actual molding does not generate deformation of the preform.

Le processus de moulage proprement dit peut alors démarrer (étape E10). A cet effet, comme indiqué précédemment, la préforme fibreuse consolidée est placée dans le moule d'injection (étape E10-1), selon un mode de réalisation qui ne fait pas partie de la présente invention. Bien entendu, cette étape, ainsi que l'étape E20-6 d'éjection de la préforme de l'outillage de consolidation, ne sont pas nécessaires si l'outillage de consolidation utilisé est le moule d'injection, comme c'est le cas dans la présente invention. Une fois le moule d'injection fermé, la résine liquide est injectée sous pression à l'intérieur de celui-ci (étape E10-2) afin d'y être polymérisée (par refroidissement - étape E10-3). La pièce obtenue est alors démoulée (étape E10-4) et éventuellement usinée aux formes finales voulues.The molding process itself can then start (step E10). For this purpose, as indicated above, the consolidated fiber preform is placed in the injection mold (step E10-1), according to an embodiment which does not form part of the present invention. Of course, this step, as well as the step E20-6 ejection of the preform of the consolidation tool, are not necessary if the consolidation tool used is the injection mold, as it is the case in the present invention. Once the injection mold has been closed, the liquid resin is injected under pressure into it (step E10-2) so as to be polymerized therein (by cooling - step E10-3). The part obtained is then demolded (step E10-4) and optionally machined to the desired final shapes.

On notera que la pré-consolidation de la préforme fibreuse peut être en soi une pièce finie et le processus d'injection proprement dit permettra d'ajouter des fonctionnalités spécifiques à celles-ci (par injection et surmoulage d'éléments dans la pièce tels que des clips de fixation, des fûts pour le vissage, des talons métalliques, des nervures de positionnement, etc.).It will be noted that the pre-consolidation of the fibrous preform can itself be a finished part and the actual injection process will make it possible to add specific functionalities to these (by injection and overmolding of elements in the part such as fastening clips, drums for screwing, metal heels, positioning ribs, etc.).

Claims (7)

  1. A method of injection molding a part made of composite material comprising fiber reinforcement densified by a matrix, the method comprising, in succession, placing (E10-1) a fiber preform in an injection mold, injecting (E10-2) a thermoplastic resin under pressure so as to impregnate the preform, and polymerizing (E10-3) the resin, the method begin characterized in that the fiber preform is consolidated in the injection mold prior to injecting the resin.
  2. A method according to claim 1, including a consolidation step (E20) of consolidating the fiber preform prior to injecting the resin into the injection mold, this consolidation step comprising:
    • making (E20-2) a fiber preform within which a consolidation resin is present;
    • placing (E20-2) the fiber preform in the injection mold;
    • heating (E20-3) the injection mold to the melting temperature of the consolidation resin present within the fiber preform; and
    • solidifying (E20-5) the consolidation resin.
  3. A method according to claim 2, wherein making a fiber preform within which a consolidation resin is present comprises inserting consolidation resin yarns while weaving the fiber preform.
  4. A method according to claim 2, wherein making a fiber preform within which a consolidation resin is present comprises dusting the fiber preform with a consolidation resin in powder form.
  5. A method according to claim 2, wherein making a fiber preform within which a consolidation resin is present comprises making a fiber preform using yarns coated in consolidation resin.
  6. A method according to any one of claims 2 to 5, wherein the step of consolidating the fiber preform further comprises applying compacting pressure to the fiber preform in the injection mold (E20-4).
  7. A method according to any one of claims 2 to 6, wherein the consolidation resin is identical to the resin injected into the injection mold.
EP14755864.7A 2013-07-22 2014-07-21 Method for injection molding a part made of a composite material having advance pre-consolidation of the fibrous preform Active EP3024639B1 (en)

Applications Claiming Priority (2)

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FR1357193A FR3008642B1 (en) 2013-07-22 2013-07-22 INJECTION MOLDING PROCESS OF A COMPOSITE MATERIAL PART WITH PRIOR PRE-CONSOLIDATION OF THE FIBROUS PREFORM
PCT/FR2014/051876 WO2015011389A1 (en) 2013-07-22 2014-07-21 Method for injection molding a part made of a composite material having advance pre-consolidation of the fibrous preform

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US11745391B2 (en) 2015-04-16 2023-09-05 Response Technologies, Llc Method of manufacturing complex-shaped, flexible, and reusable tanks
US10688775B2 (en) * 2015-04-16 2020-06-23 Response Technologies, Llc Method of manufacturing containment bladders
FR3068640B1 (en) * 2017-07-07 2019-08-02 Safran Aircraft Engines METHOD AND TOOLS FOR MANUFACTURING A PIECE BY RESIN INJECTION IN A WOVEN FIBER PREFORM
US11235499B2 (en) 2019-02-01 2022-02-01 GM Global Technology Operations LLC Natural fiber layer with injection molded surface
FR3098749B1 (en) * 2019-07-19 2023-01-20 Institut De Recherche Tech Materiaux Mettalurgie Procedes Process for manufacturing preforms for composite materials

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US20070023975A1 (en) * 2005-08-01 2007-02-01 Buckley Daniel T Method for making three-dimensional preforms using anaerobic binders
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FR3008642A1 (en) 2015-01-23
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EP3024639A1 (en) 2016-06-01
WO2015011389A1 (en) 2015-01-29

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